Medium Voltage 400A Contactor - Series E and F

Transcription

1 User Manual Original Instructions Medium Voltage 400A Contactor - Series E and F Catalog Number 1502

2 Important User Information Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards. Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice. If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited Throughout this manual, when necessary, we use notes to make you aware of safety considerations. WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence. IMPORTANT Identifies information that is critical for successful application and understanding of the product. Labels may also be on or inside the equipment to provide specific precautions. SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present. BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures. ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

3 Table of Contents Preface Summary of Changes About This Publication What This Manual Contains Additional Resources Chapter 1 Product Description Contactor Description Series Letter Details Vacuum Bottle Description Electrically Held Contactor Operation IntelliVAC and IntelliVAC Plus Controlled Contactors Electromechanical Relay Controlled Contactors Mechanically Latched Contactor Operation IntelliVAC and IntelliVAC Plus Controlled Contactor Electromechanical Relay Controlled Contactor Contactor Identification Catalog Number Explanation Contactor Dropout Times Specifications Product Approvals Chapter 2 Receiving and Handling Receiving Preliminary Inspection Handling Pre-energization Inspection Storage Vacuum Bottle Integrity Test Insulation Resistance Test Chapter 3 Installation Mounting Electrical Connections Wiring and Schematic Diagrams Chapter 4 Maintenance Tool Requirements Recommended Torque Values Routine Maintenance Cleaning Main Contact Inspection HiPot and Insulation Resistance Test Lubrication Rockwell Automation Publication 1502-UM052J-EN-P - December

4 Table of Contents Vacuum Bottle Replacement Coil Replacement Procedure Auxiliary Contact Setup Procedure Mechanically Latched Contactor Trip Coil Replacement Procedure 44 Parts Procedure Mechanically Latched Contactor Setup Procedure Altitude Adjustment Chapter 5 Troubleshooting Troubleshooting and Contactor Coil Resistance Chapter 6 Spare Parts Bulletin 1502 Spare Parts Diagrams and Chart Index Rockwell Automation Publication 1502-UM052J-EN-P - December 2017

5 Preface Summary of Changes This table contains the changes made to this revision. Topic Page Updated procedure for replacing the vacuum bottles 38 About This Publication This manual pertains to the Allen-Bradley Bulletin 1502, Series E and F version 400 A vacuum contactors. For earlier product series letters, contact your local Rockwell Automation representative. Series E and F vacuum contactors are intended for use with electromechanical (relay) control circuits and with IntelliVAC and IntelliVAC Plus control modules. See publications 1503-UM053 and 1503-UM054 respectively. This manual is intended for engineers or technicians that are directly involved in the installation, connection, energizing, and maintenance of the Medium Voltage 400 A Contactor. What This Manual Contains This manual contains the following sections: Contactor description, including dropout times and specifications Information on how to receive, handle, and store the contactor How to mount the contactor, which includes typical electrical and wiring diagrams Tools that are required to maintain the contactor, recommended torque values, and how to perform routine maintenance tasks Troubleshooting section that outlines symptoms, possible causes, and how to remedy them Spare Parts list Rockwell Automation Publication 1502-UM052J-EN-P - December

6 Preface Additional Resources These documents contain additional information concerning related products from Rockwell Automation. Resource Medium Voltage Controllers, 400A One-High Cabinet, Standard and Arc-Resistant Enclosure, publication 1512A- UM100 Medium Voltage Controllers, 200/400A Two-High Cabinet, Standard and Arc-Resistant Enclosure, publication UM055 IntelliVAC Contactor Control Module User Manual, publication 1503-UM053 IntelliVAC Plus Contactor Control Module User Manual, publication 1503-UM054 Industrial Automation Wiring and Grounding Guidelines, publication Product Certifications website, overview.page Description Provides information on installation, maintenance, and spare parts for standard and arc resistant enclosures Provides information on installation, maintenance, and spare parts for standard and arc resistant enclosures Provides information on receiving and storage, installation, setup, monitoring, and spare parts for the IntelliVAC Contactor Control Module Provides information on receiving and storage, installation, wiring, programming, and troubleshooting for the IntelliVAC Plus Contactor Control Module Provides general guidelines for installing a Rockwell Automation industrial system. Provides declarations of conformity, certificates, and other certification details. You can view or download publications at To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative. 6 Rockwell Automation Publication 1502-UM052J-EN-P - December 2017

7 Chapter 1 Product Description Contactor Description The Allen-Bradley Bulletin A vacuum contactors are designed for applications in the V AC range. The contactor is suitable for all types of loads, for example: three-phase motors, transformers, power capacitors, and resistive heat loads. The contactor uses three interrupters (referred to as vacuum bottles) operated by an electromagnet assembly through a mechanical linkage. They are resistant to most adverse atmospheric conditions and provide long mechanical and electrical life. The contactors are used in various motor control and drive configurations, such as full-voltage non-reversing, full-voltage reversing, two-speed, reduced voltage, synchronous, drive input/output, and bypass applications. They are fixed-mounted within the structures and the line and load terminations are made at the rear of the device. In most configurations, the main contactor is mechanically interlocked with the external operating handle and isolation switch. Bulletin 1502 vacuum contactors are designed for use with the IntelliVAC and IntelliVAC Plus control modules (see publications 1503-UM053 and 1503-UM054). Certain contactor models are configured for use with electromechanical (relay) control panels. There are physical differences between contactors that are designed for IntelliVAC and IntelliVAC Plus control versus those intended to be operated using electromechanical relay controls (see Catalog Number Explanation on page 12). Series Letter Details The series letter of the Bulletin 1502 contactor is shown on the label that is located on the front of the armature plate (Figure 4). The catalog number, along with the series letter, define the product s electrical and mechanical configuration. This information must be used to select the appropriate repair or replacement parts. Electromechanical relay controlled, electrically held contactors moved from Series D to Series E with the inclusion of mechanical vacuum bottle braces. Electromechanical relay controlled, mechanical-latch contactors were moved from Series E to Series F with the inclusion of mechanical vacuum bottle braces. Rockwell Automation Publication 1502-UM052J-EN-P - December

8 Chapter 1 Product Description IntelliVAC and IntelliVAC Plus controlled electrically held and mechanically latched contactors were moved from Series E to Series F with the inclusion of mechanical vacuum bottle braces. Figure A Contactor Vacuum Bottle Description Each vacuum bottle (Figure 2) consists of two contacts that are enclosed in a ceramic housing: an upper contact that is mounted to a fixed shaft, and a lower contact that is mounted to a movable shaft. A stainless steel bellow helps the vacuum integrity of the bottle, while letting the lower contact move towards and away from the fixed contact. Figure 2 - Vacuum Bottle Cross Section Fixed Shaft Ceramic Arc Shield Contacts Bellows Contact Wear Indicator Line Bearing Movable Shaft 8 Rockwell Automation Publication 1502-UM052J-EN-P - December 2017

9 Product Description Chapter 1 Electrically Held Contactor Operation IntelliVAC and IntelliVAC Plus Controlled Contactors The electrically held contactor consists of three vacuum bottles. An electromagnet assembly and a mechanical linkage are used to close the contacts. When the IntelliVAC or IntelliVAC Plus control module receives a close command, the contactor coils (two connected in series) are energized, and the current creates an electromagnet with the coils. The electromagnet pulls the armature plate towards the core of the coils, which rotates the shaft and causes the actuator plate to move upwards. As the actuator plate moves, it pushes the insulator and each vacuum interrupter s movable shaft up, which closes the contacts in the vacuum bottle. The IntelliVAC or IntelliVAC Plus control module supplies the current required to close the coils for approximately 200 milliseconds. Afterward, the coil current is reduced to a lower hold-in value. When the close command is removed from the IntelliVAC or IntelliVAC Plus control module (Open), the coils are de-energized, which opens the contactor. Electromechanical Relay Controlled Contactors When the main pilot relay (CR1) in the control circuit is energized, the circuit energizes an electromagnet in the closing coil and in the hold-in coil (Figure 18). The electromagnet pulls the armature plate towards the core of the coils, which rotates the shaft and causes the actuator plate to move upwards. As the actuator plate moves, it pushes the insulator and each vacuum interrupter s movable shaft up, which closes the contacts in the vacuum bottle. The control circuit economizing auxiliary contacts, on the left side of the contactor, change from the normally closed state to the normally open state as the contactor closes, which de-energizes the closing coil. The hold-in coil remains energized and keeps the contactor closed. Deenergizing the hold-in coil opens the contactor. IMPORTANT The standard electrically held contactor requires an external 120V AC or 240V AC control relay and rectification circuit to control the standard DC closing and hold-in coils on the contactor (see Figure 19). Rockwell Automation Publication 1502-UM052J-EN-P - December

10 Chapter 1 Product Description Figure 3 - Electrically Held Vacuum Contactor Operation Control Transformer Fuse Clip Insulator Armature Plate and Shaft Auxiliary Actuator Control Wire Plug Armature Stop Bracket Line Terminal Vacuum Bottle Load Terminal Flexible Bus Return Spring Actuator Plate Gap Adjustment Screw Magnet Coil Assembly Mechanically Latched Contactor Operation The mechanically latched contactor operates in much the same way as the electrically held (Figure 3) with only a few exceptions. IntelliVAC and IntelliVAC Plus Controlled Contactor Once the contactor is fully closed, a spring-loaded mechanism moves a roller against the armature plate to hold it against the electromagnetic core. The contactor can be opened electrically by energizing a trip coil (via IntelliVAC or IntelliVAC Plus open [TCO] output) which pulls the latch away from the armature, or by a push button that mechanically releases the contactor. The push button is mounted on the power cell door. Electromechanical Relay Controlled Contactor Once the contactor is fully closed, a spring-loaded mechanism moves a roller against the armature plate to hold it against the electromagnetic core. The control circuit auxiliary contact, on the left side of the contactor, changes from the normally closed state to the normally open state as the contactor closes. This action de-energizes the relay that controls the closing coils (see Figure 18). The contactor can be opened electrically by energizing a trip coil that pulls the latch away from the armature, or by a push button that mechanically releases the contactor. The push button is mounted on the power cell door. 10 Rockwell Automation Publication 1502-UM052J-EN-P - December 2017

11 Product Description Chapter 1 The electromechanical relay controlled mechanical latch contactor requires external 120V AC or 230V AC control relays and rectification circuit to control the standard DC closing and trip coils on the contactor (when IntelliVAC or IntelliVAC Plus is not used). See Figure 19. WARNING: The Rockwell Automation relay control panel (1503C-XXX or 1503E-CXXX) is required for reliable operation of the contactor within its published specifications. The relays break the DC current that is drawn by the closing coil, holding coil, and trip coil. The relays make sure the pick-up and drop out voltages are coordinated with the pick-up and drop out voltages of the contactor. This provides reliable operation of the circuit in undervoltage conditions. The use of alternative control relays is not supported or recommended. Alternative relays do not provide the necessary control timings necessary to provide reliable operation and coordination with all power fuses used in combination with the contactors. Contactor Identification Each contactor is identified with a rating label (Figure 4) attached to the armature plate at the front of the contactor. The rating label information includes the Catalog Number (Cat.) Series Letter (Ser.) Voltage Rating, Non- Enclosed Current Rating, Interrupting Capacity, Altitude Range (in meters), CSA, UL, and CE markings. Figure 4 - Contactor Rating Label (400 A) Rockwell Automation Publication 1502-UM052J-EN-P - December

12 Chapter 1 Product Description Catalog Number Explanation The following catalog number explanation is used to identify the contactor and must be used when contacting your local Rockwell Automation sales office for assistance. Position V 4 D B D A a b c d e f g Contactor Type and Interlock V Vacuum, electromechanical relay controlled VC Vacuum, optimized for IntelliVAC control Contactor Size A Nominal Line Voltage D 7200V a b c d Control Circuit or Voltage Transformer Primary Fuse Mounting Provisions B 5000V C 7200V Coil Voltage D 110V DC E 207V DC e A f Function 3-pole, electrically held contactor B 3-pole, mechanically latched contactor with electrical and mechanical release C 3-pole, electrically held contactor with fast drop-out (1) (1) Controlled by electromechanical relay. Altitude Code (m) (1) (1) Only with VC contactor type (Position 1 in Catalog Number). g Contactor Dropout Times The IntelliVAC or IntelliVAC Plus contactor control module (publications 1503-UM053 and 1503-UM054) varies the speed at which the electrically held vacuum contactor opens. When electromechanical relays are used to control the electrically held contactor, there are two speeds available: normal dropout time and fast dropout time. The opening speed is controlled by changes to the onboard contactor control circuity (see Figure 13 through Figure 16). Contactors that are configured for faster dropout times are used for specific applications if faster uncoordinated action is required. 12 Rockwell Automation Publication 1502-UM052J-EN-P - December 2017

13 Product Description Chapter 1 Contactors with normal dropout times must be used in coordination with medium voltage power fuses. The dropout time must be longer than the Total Clearing Time of the medium voltage power fuses being applied in combination with the vacuum contactor. Damage to the contactor can occur if this coordination is not addressed appropriately. All mechanically latched contactors are designed with the fast dropout time. Specifications Table 1 - Voltage Rating (1) Maximum Rated Voltage 7200 System Voltages 2400, 3300, 4160, 4800, 6600, 6900 Dielectric Voltage Withstand Rating For 60 seconds (kv) 18.2/20 (IEC) Basic Impulse Level (B.I.L.) Withstand Phase to Ground, Phase to Phase (kv) Frequency Ratings Hertz 50/60 (1) The voltage ratings listed are valid up to 1000 m (3300 ft). See Table 8 for ratings above this altitude. 60 Table 2 - Current Ratings (1) Rated Continuous Current (A) 400 Maximum interrupting current rating 2400V (RMS Sym A) V (RMS Sym A) V (RMS Sym A) (2) 6000 Maximum interrupting MVA rating 2400V (Sym MVA) V (Sym MVA) V (Sym MVA) (2) 75 Short circuit withstand at rated voltage Current Peak ½ cycle (ka) 55 Short time current rating capability For 1 second (ka) 6.0 For 30 seconds (ka) 2.4 Chop current (average rms amperes) 0.5 Make and Break Capability at Rated Voltage (ka) 4.0 Ambient Temperature C 40 (1) The current ratings that are listed are valid up to 1000 m (3300 ft). See Table 8 for ratings above this altitude. (2) The IEC rating at 7200V (RMS Sym.) is 5300 A / 66 MVA. Rockwell Automation Publication 1502-UM052J-EN-P - December

14 Chapter 1 Product Description Table 3 - Contactor Coil Data Control Voltage (V CTL ) Coil Voltage (V CL ) Electromechanical Relay Controlled (Mechanical Latch) 120V AC 110V DC Close current inrush (A DC ) 5.6 Pilot Relay (CR1) pick-up voltage 102 Minimum trip coil voltage (VAC) 84 Trip coil current (A) 6 Electromechanical Relay Controlled (Electrically Held) 120V AC 110V DC Close current inrush (A DC ) 7.3 Economized holding current (A DC ) 0.13 Minimum CR1 coil pick-up voltage (VAC) 102 CR1 coil drop-out voltage (VAC) 75 Electromechanical Relay Controlled (Mechanical Latch) 230V AC 210V DC Not available at this control voltage Electromechanical Relay Controlled (Electrically Held) 230V AC 210V DC Close current inrush (A DC ) 8.3 Economized holding current (A DC ) 0.11 Minimum CR1 coil pick-up voltage (V AC) 190 CR1 coil drop-out voltage (V AC) 140 IntelliVAC and IntelliVAC Plus Control (Electrically Held & Mechanical Latch) V AC or V DC (1) V AC: V CL = 2 V DC: V CL = V CTL x V CTL (max.) Close current (A DC, 200 milliseconds) 4.3 Hold current (A DC ) 0.48 Pick-up voltage (1) 95 Drop-out voltage (1) 75 Trip current (A DC, 200 milliseconds) 5.5 Trip voltage (1) 70 (1) Control voltage, as measured at the input of the IntelliVAC or IntelliVAC Plus control module or the primary voltage to the pilot relay control circuit. Table 4 - Operational Characteristics Mechanical life (operations) x 1000 (1) Electrically held 2500 Mechanical latch 100 Electrical life (operations) x 1000 (1) 1000 Switching frequency (operations per hour) Electrically held 600 Mechanical latch 150 (1) Provided that regular maintenance is performed, as detailed in this manual. 14 Rockwell Automation Publication 1502-UM052J-EN-P - December 2017

15 Product Description Chapter 1 Table 5 - Opening and Closing Times Maximum closing time (120V AC) (1) Maximum opening time (120V AC) (2) Maximum opening time (120V AC) (3) Electromechanical (Relay) Controlled 50 Hz or 60 Hz (ms) 160 (1) Control/Pilot relay, other than the standard Rockwell Automation Control Panel assembly (1503C-E4_ or 1503C-M4D), must provide a constant closing signal for at least this period of time. The use of control components other than Rockwell Automation products is not recommended and may pose reliability concerns. (2) Mechanical latched. 50 Hz or 60 Hz (ms) Hz or 60 Hz (ms) 160 IntelliVAC and IntelliVAC Plus Control (Electrically Held & Mechanical Latch) Maximum closing time (50 60 Hz) 120 / 240V AC (ms) 100/70 Maximum opening time (without delay, for Hz) (4) 120 / 240V AC (ms) 60 (3) Electrically held, normal dropout. (4) A contactor drop-out delay may be configured with the IntelliVAC or IntelliVAC Plus control module (refer to publications 1503-UM053 and 1503-UM054). Table 6 - Capacitor Switching (max. kvar) System Voltage 2400V V V 2000 Table 7 - General Standard Altitude Capability (1) (2) Contactor Weight Auxiliary Contact Rating Auxiliary Contacts on the Vacuum Contactor (max.) (3) m ( ,500 ft) 21.8 kg (48 lb) A600 3 N.O., 3 N. C. (1) The voltage and current ratings that are listed are valid up to 1000 m (3300 ft). See Table 8 for ratings above this altitude. (2) The full altitude range is available with the IntelliVAC or IntelliVAC Plus control module only, and the IntelliVAC or IntelliVAC Plus is to be configured accordingly (refer to publications 1503-UM053 and 1503-UM054). The standard mechanical latch contactors, if used with electromechanical control, are designed for m ( ft). Higher altitudes are possible by changing the contactor return springs (refer to Catalog Number Explanation for suitable catalog numbers). (3) The number of contactor auxiliary contacts depends on the contactor type. Some of the contacts are used in the typical control schemes used. Rockwell Automation Publication 1502-UM052J-EN-P - December

16 Chapter 1 Product Description Table 8 - Altitude Derating Altitude Rating Max. Continuous Current Rating (2) Reduce B.I.L. Withstand Rating by: m ( ft) (1) m ( ft) m ( ft) m ( ft) m ( ,200 ft) m (13,201 16,500 ft) 400 A 400 A 390 A 6.0 kv 380 A 12.0 kv 370 A 18.0 kv 360 A 24.0 kv (1) Only supported with IntelliVAC or IntelliVAC Plus controlled contactors (2) Open rating. When enclosed in a controller, see the appropriate controller manual for enclosed contactor derating values. Product Approvals UL347 CSA22.2 No. 14 and T.I.L. D-21 IEC CE Marked 16 Rockwell Automation Publication 1502-UM052J-EN-P - December 2017

17 Chapter 2 Receiving and Handling Receiving The contactors have been tested both mechanically and electrically before leaving the factory. Immediately upon receiving the contactor, remove the packing material and check the contactor for possible damage from shipping. If damage is found, do not discard the packaging materials and, if possible, note the damage on the Bill of Lading before accepting the shipment. Report any damage immediately to the claims office of the common carrier. Provide a description of the damage and as much identification as possible. Preliminary Inspection Check for any cracks or breaks that were caused by impact. Push armature plate to verify that the mechanisms are functional. Use a HiPot tester to test vacuum bottle integrity (refer to Vacuum Bottle Integrity Test on page 18) Handling The contactor weighs approximately 21.8 kg (48 lb). When transporting the contactor over longer distances or for sustained lifting, use a forklift. When a forklift is used to handle the equipment, adhere to the following precautions: Keep the contactor in an upright position. Carefully balance the contactor on the forks. Use a safety strap to steady the contactor and avoid shifting or being tipped. Avoid excessive speeds and sudden starts, stops, and turns. Never lift a contactor above an area where personnel are located. Rockwell Automation Publication 1502-UM052J-EN-P - December

18 Chapter 2 Receiving and Handling Pre-energization Inspection Before placing the contactor in service, inspect for possible damage sustained in transit or maintenance:. Check housing for any cracks or breaks. Push the armature plate and rotating shaft to verify that the mechanism is in good working order. Inspect the contactor for dirt, stray or loose hardware, tools, or metal chips. Vacuum if necessary. Storage To store the contactor before it is in service, store it in a clean, dry area, free from dust and condensation. Do not store contactor outdoors. Storage temperature must be between C ( F). If storage temperature fluctuates or if humidity exceeds 85%, use space heaters to prevent condensation. Vacuum Bottle Integrity Test The internal dielectric condition and vacuum integrity of the vacuum bottles is determined by this test. ATTENTION: Do not apply a voltage higher than 25,000V across the open contacts of a vacuum bottle. Dangerous x-ray emissions can be produced. ATTENTION: Vacuum bottles are thoroughly tested at the factory; however, damage during shipment can occur. It is important to perform the vacuum bottle integrity test before energizing the contactor for the first time, and before it is returned to service after maintenance or repair. The test may result in personal injury or damage to the equipment if the vacuum bottle integrity fails. ATTENTION: A high-voltage test is potentially hazardous. Use caution when performing the Hi-pot test. Failure to do so may result in severe burns, injury, or death. High-potential test instruments can be purchased to perform the vacuum bottle integrity test. An insulation resistance tester cannot be used to measure vacuum integrity because the voltage is too low. One of the following AC Hipot testers is recommended as a test instrument. Manufacturer Mitsubishi Type VI #4U17 Jennings Model JHP-70A Hipotronics Model 7BT 60A Address Chicago, Ill., USA San Jose, CA., USA Brewster, NY, USA 1. Clean the outside of the vacuum bottles with a lint-free cloth or industrial wipe before performing the test. 18 Rockwell Automation Publication 1502-UM052J-EN-P - December 2017

19 Receiving and Handling Chapter 2 2. The contactor can be tested while it is in the power cell. The line connection of the contactor must be disconnected and the ground lead from the Hi-pot tester must be connected to the load side of the contactor. Any fuses in the top of the contactor must be removed. 3. With the contactor in the open position, connect the test leads to the contactor power terminals as shown in Figure 5. It is recommended that an AC Hi-pot tester be used. Apply 16 kv for 60 seconds and monitor the leakage current. It must not exceed 5 ma. Test each vacuum bottle individually. 4. If no breakdown occurs, the vacuum bottle is in an acceptable condition. If a breakdown occurs, repeat the test once more. If the vacuum bottle fails a second time, it must be replaced. If no breakdown occurs in the second test, the vacuum bottle is in an acceptable condition. ATTENTION: If one vacuum bottle fails, Rockwell Automation recommends replacing all three vacuum bottles, if the unit has been in service. 5. After the high potential voltage is removed from the vacuum bottles, the metal end caps of the vacuum bottles must be discharged with a grounding rod. Figure 5 - Vacuum Bottle Integrity Test Circuit Vacuum Checker Vacuum Contactor in Open Position The allowable leakage current value of 5 ma is exclusive of leakage due to test equipment leads. The test setup leakage can be determined by running the dielectric test with test leads not connected to the contactor and noting the maximum leakage current. If this value is more than 2 ma, it must be added to the 5 ma limit when testing the vacuum bottles. Rockwell Automation Publication 1502-UM052J-EN-P - December

20 Chapter 2 Receiving and Handling Rockwell Automation does not recommend a DC Hi-pot test. The values that are obtained during the test are not a reliable indication of vacuum bottle integrity. Some specific DC GO-NO GO testers may provide suitable defective readings. A DC Hi-pot test is unreliable because of Cathode Ray Tube Effect. This phenomenon occurs when one contact of the vacuum bottle has a deformity, such as a burr or deposit, while the other contact remains flat and true. This deformity creates leakage currents, which flow from a small surface to a large surface in one direction and vice versa when the polarity of the tester is changed. The resultant current is large in one direction, which would incorrectly indicate a faulty vacuum bottle. A DC test can verify some degree of vacuum integrity. It does not give any indication of the degree of vacuum, since the contact surface can change with each operation of the vacuum contactor. However, an AC test provides a reliable vacuum integrity indication. Additionally, the degree of vacuum within the bottle can be determined by comparing initial test results to the present readings. Increases in leakage current indicate a reduction in vacuum within the vacuum bottle. For these reasons, Rockwell Automation recommends an AC test as the preferred method of a vacuum bottle test. A suitable GO-NO GO DC test unit is: Manufacturer Programma, Model VIDAR Address Santa Rosa, CA, USA Insulation Resistance Test Use a 1000V insulation resistance tester to verify that the resistance from phase-to-phase or from phase-to-ground is greater than 500 megohms. 20 Rockwell Automation Publication 1502-UM052J-EN-P - December 2017

21 Chapter 3 Installation Mounting The electrically held and the mechanically latched contactors are fixedmounted in the cabinet. Two retaining tabs at the rear of the molded base can be used for mounting. The two mounting slots at the front of the molded base secure the contactor with 1/4 in. bolts. The appropriate mounting configuration is provided inside the power cells of Allen-Bradley controllers. If the contactor is supplied as an OEM component for installation in a custom application, refer to the dimensional information in Figure 6. If the contactor is mounted in an enclosure designed by an OEM, there must be a minimum of 3 in. (76 mm) of air space between live parts (terminals and vacuum bottles) and the enclosure. Figure 6 - Contactor Mounting Details (dimensions are in inches [millimeters]) 0.75 [19] [336] 8.64 [219] 4.96 [126] [438] 8.53 [217] 5.00 [127] 3.15 [80] 4.25 [108] 4.25 [108] Front View Cutaway View 0.37 [9] 0.91 [23] 1.36 [35] [267] 0.37 [9] [7] wide slots 7.87 [200] 2.12 [54] 8.00 [203] 0.98 [25] Bottom View Rockwell Automation Publication 1502-UM052J-EN-P - December

22 Chapter 3 Installation Figure 7 - Mechanical Latch Dimensions (Optional) Contactor Electrical Connections A wire harness connects the control wiring to the contactor from the low voltage control panel. The harness connects to a wire plug on the lower left side of the contactor. If the contactor is supplied as an OEM component for installation in a custom application, the following two control options and a connecting wire harness are available from Rockwell Automation. IntelliVAC and IntelliVAC Plus control modules Electromechanical control panel Connect incoming power to the line side terminals at the top, rear of the contactor near the control fuse clips. Use 3/8 in. (10 mm) bolts torqued to 20 lb ft (292 N m) to secure the connection. Connect outgoing power to the load side terminals halfway down the rear of the contactor. Use 3/8 in. (10 mm) bolts torqued to 20 lb ft (292 N m) to secure the connection. For mechanically latched contactors, the manual trip button in the cabinet door must be in line with the trip lever on the contactor. 22 Rockwell Automation Publication 1502-UM052J-EN-P - December 2017

23 Installation Chapter 3 Figure 8 - Electrical Connections (Rear View) Control Circuit Transformer Primary Fuse Clips Line Side Terminals Load Side Terminals Control Wire Plug Rockwell Automation Publication 1502-UM052J-EN-P - December

24 Chapter 3 Installation Wiring and Schematic Diagrams Figure 9 - Wiring Diagram - Electrically Held Contactor (for use with IntelliVAC and IntelliVAC Plus Control Modules Only) Yellow Black Yellow Black 120V Contactor Plug Power Wiring Control Transformer Primary Fuse Holders A - N - Pins D, P - No Connections Schematic 400 A Vacuum Contactor Auxiliary Contacts 24 Rockwell Automation Publication 1502-UM052J-EN-P - December 2017

25 Installation Chapter 3 Figure 10 - Wiring Diagram - Mechanical Latch Contactor (for use with IntelliVAC and IntelliVAC Plus Control Modules Only) Yellow Black Yellow Black White Blue Auxiliary Contacts Power Circuit Control Transformer Primary Fuse Holders A, B, C, D, I - Sockets All Others - Pins Auxiliary Contacts Contactor Shown in Open (Tripped) Condition CC - Closing Coil TC - Trip Coil Rockwell Automation Publication 1502-UM052J-EN-P - December

26 Chapter 3 Installation Figure 11 - Wiring Diagram - Mechanical Latch Contactor (for use with Electromechanical Control Panel Only) Yellow Black Yellow Black White Blue Auxiliary Contacts Power Circuit Control Transformer Primary Fuse Holders C, D, I - Sockets All Others - Pins Auxiliary Contacts Contactor Shown in Open (Tripped) Condition CC - Closing Coil TC - Trip Coil 26 Rockwell Automation Publication 1502-UM052J-EN-P - December 2017

27 Installation Chapter 3 Figure 12 - Wiring Diagram - Electrically Held Contactor, 120V AC, Normal Dropout Time, (for use with Electromechanical Control Panel Only) Yellow Black Yellow Blue Auxiliary Contacts Power Circuit Control Transformer Primary Fuse Holders A - N - Pins Schematic 400 A Vacuum Contactor 120V Coil, Normal Dropout Auxiliary Contacts CC - Closing Coil HC - Holding Coil Rockwell Automation Publication 1502-UM052J-EN-P - December

28 Chapter 3 Installation Figure 13 - Wiring Diagram - Electrically Held Contactor, 230V AC, Normal Dropout Time, (for use with Electromechanical Control Panel Only) Yellow Black Yellow Blue Auxiliary Contacts Power Circuit Control Transformer Primary Fuse Holders B, C, D, E, F, G, H, I, J, K, N - Pins A, L, M - Sockets P - Not used Schematic 400 A Vacuum Contactor 230V Coil, Normal Dropout Auxiliary Contacts CC - Closing Coil HC - Holding Coil 28 Rockwell Automation Publication 1502-UM052J-EN-P - December 2017

29 Installation Chapter 3 Figure 14 - Wiring Diagram - Electrically Held Contactor, 120V AC, Fast Dropout Time, (for use with Electromechanical Control Panel Only) Yellow Black Yellow Blue Auxiliary Contacts Power Circuit Control Transformer Primary Fuse Holders A - N - Pins Schematic 400 A Vacuum Contactor 230V Coil, Fast Dropout Auxiliary Contacts CC - Closing Coil HC - Holding Coil Rockwell Automation Publication 1502-UM052J-EN-P - December

30 Chapter 3 Installation Figure 15 - Wiring Diagram - Electrically Held Contactor, 230V AC, Fast Dropout Time, (For Use with Electromechanical Control Panel Only) Yellow Black Yellow Blue Auxiliary Contacts Power Circuit Control Transformer Primary Fuse Holders B, C, D, E, F, G, H, I, J, K, N - Pins A, L, M - Sockets P - Not used Schematic 400 A Vacuum Contactor 230V Coil, Fast Dropout Auxiliary Contacts CC - Closing Coil HC - Holding Coil 30 Rockwell Automation Publication 1502-UM052J-EN-P - December 2017

31 Installation Chapter 3 Figure 16 - Typical Schematic Diagram for 400 A Full-Voltage Non-Reversing (FVNR) Controller With IntelliVAC Control and Electrically Held Contactor L1 L2 L3 GRD M CT1 CT2 CT3 T1 T2 T3 2400V-6900V 3Ø, 50/60Hz POWER BUS GRD BUS ISOLATING SWITCH DOOR INTERLOCK CURRENT LIMITING POWER FUSES H1 CPT 500VA ISa 5 7 X1 H2 X2 CURRENT LIMITING PRIMARY FUSES OL OVERLOAD X (5) (6) ISb A 2.0A E M F I M J 35 EXTRA AUXILIARY CONTACTS 32 G M H K M L STOP STOP 1 # MOV D NOTE: NORMAL X OFF TEST (1) (2) (7) (8) X TEST SUPPLY POINT 10 TS V 50/60Hz (3) (4) X A M B EC M-IV TCO 11 6 AUX CCO N MAIN CONTACTOR MOV M M C L1 G L2/N START START D D 1A M-IV CLOSE OL M-IV CONTACTOR STATUS D RUN 12 D OFF INTELLIVAC NOTES: OUTPUT RELAY CONTACTS SHOWN WITHOUT CONTROL POWER APPLIED. THE FOLLOWING FACTORY INSTALLED CONFIGURATION/POWER-UP STATES ARE IN EFFECT: CONTACTOR STATUS - FAIL SAFE MODULE STATUS - FAIL SAFE INTELLIVAC TO BE PROGRAMMED/CONFIGURED BY THE CUSTOMER BEFORE START-UP. REMOVE JUMPER WHEN CONNECTING REMOTE EQUIPMENT. REMOTE EQUIPMENT LOW VOLTAGE DOOR MOUNTED DEVICE "IEEE" NUMBER FOR PROTECTIVE DEVICE METAL OXIDE VARISTOR CUSTOMER WIRING REFER TO DIMENSION DRAWING FOR COMPONENT SIZING NOT - Rockwell Automation Publication 1502-UM052J-EN-P - December

32 Chapter 3 Installation Figure 17 - Typical Schematic Diagram for 400 A Full-Voltage Non-Reversing (FVNR) Controller With IntelliVAC Control and Mechanical Latch Contactor L1 L2 L3 GRD M CT1 CT2 CT3 T1 T2 T3 2400V-6900V 3Ø, 50/60Hz POWER BUS GRD BUS ISOLATING SWITCH DOOR INTERLOCK CURRENT LIMITING POWER FUSES H1 CPT 500VA X1 5 H2 X2 CURRENT LIMITING PRIMARY FUSES MANUAL TRIP 42 OL OVERLOAD ISa 7 6 X (5) (6) ISb 9 4.0A 2.0A 14 1A 32 G M H 33 M L 37 EXTRA AUXILIARY CONTACT 30 E M F 31 M J N M P 34A NORMAL X OFF (1) (2) (7) (8) X TEST SUPPLY POINT 10 TS V 50/60Hz (3) (4) 15 M K EC M-IV TCO 11 6 AUX CCO D 17 C MAIN CONTACTOR M MOV TC MOV CC M B A G L1 L2/N OL ON 1B D 2 OFF D 3 OL 1 M-IV CLOSE 1 M-IV OPEN D RUN D OFF 1 INTELLIVAC NOTES: OUTPUT RELAY CONTACTS SHOWN WITHOUT CONTROL POWER APPLIED. THE FOLLOWING FACTORY INSTALLED CONFIGURATION/POWER-UP STATES ARE IN EFFECT: CONTACTOR STATUS - FAIL SAFE MODULE STATUS - FAIL SAFE CC TC MOV NOTE: D # INTELLIVAC TO BE PROGRAMMED/CONFIGURED BY THE CUSTOMER BEFORE START-UP. CLOSING COIL TC-TRIP COIL LOW VOLTAGE DOOR MOUNTED DEVICE "IEEE" NUMBER FOR PROTECTIVE DEVICE METAL OXIDE VARISTOR CUSTOMER WIRING REFER TO DIMENSION DRAWING FOR COMPONENT SIZING NOT TEST X I - 32 Rockwell Automation Publication 1502-UM052J-EN-P - December 2017

33 Installation Chapter 3 Figure 18 - Typical Schematic Diagram for 400 A Full-Voltage Non-Reversing (FVNR) Controller With Electro-Mechanical Control and Mechanical Latch Contactor (1) L1 L2 L3 GRD M CT1 CT2 T1 T2 CT3 T3 2400V-6900V 3Ø, 50/60Hz POWER BUS GRD BUS ISOLATING SWITCH DOOR INTERLOCK CURRENT LIMITING POWER FUSES H1 CPT 500VA ISa X1 5 H2 X2 CURRENT LIMITING PRIMARY FUSES MANUAL TRIP OL OVERLOAD X (5) (6) ISb A E M J 30 1 M F G M H 32 1 M L EXTRA AUXILIARY CONTACTS 34 N M P 34A 36 I M K 36A OFF NORMAL TEST X (1) (2) (7) (8) X TEST SUPPLY POINT 10 TS V 50/60Hz (3) (4) X REC/MOV RECTIFIER + MOV 15 CR1 CR1 CR1 CR1 17A 17B MAIN CONTACTOR 17C 17 C M T D1 CC M A 20 CR2 CR2 D B 19 TC 15A R 35 OL ON 2A D 2 CR1 MAIN CONTACTOR LATCH RELAY 31 OFF OL D 3 CR2 MAIN CONTACTOR UNLATCH RELAY 33 D RUN 37 D OFF CC TC MOV NOTE: D # CLOSING COIL TC-TRIP COIL LOW VOLTAGE DOOR MOUNTED DEVICE "IEEE" NUMBER FOR PROTECTIVE DEVICE METAL OXIDE VARISTOR CUSTOMER WIRING REFER TO DIMENSION DRAWING FOR COMPONENT SIZING NOT (1) CR1 and CR2 and the wiring of their contacts into the control circuit are part of the Rockwell Automation relay control panel (1503C-XXX or 1503E-CXXX). This control panel provides reliable operation of the contactor within its published specification. Rockwell Automation Publication 1502-UM052J-EN-P - December

34 Chapter 3 Installation Figure 19 - Typical Electrical Diagram for 400 A Full-voltage Non-reversing (FVNR) Controller with Electrically Held Contactor, 120V AC (Normal Drop-out Time) (1) (1) CR1 and CR2 and the wiring of their contacts into the control circuit are part of the Rockwell Automation relay control panel (1503C-XXX or 1503E-CXXX). This control panel provides reliable operation of the contactor within its published specification. 34 Rockwell Automation Publication 1502-UM052J-EN-P - December 2017

35 Chapter 4 Maintenance Tool Requirements IMPORTANT Some components of this product incorporate imperial hardware. Rockwell Automation recommends the use of the appropriate tools to complete the maintenance procedure on these components. If you cannot obtain such tools, contact your Rockwell Automation sales office. When maintenance is performed on the vacuum contactor, the following tools are required: 3/8 in. drive ratchet wrench with extension 3/8 in. drive torque wrench Standard 3/8 in. drive sockets; 7/16 in., 1/2 in. Open-end wrenches; 7/16 in., 1/2 in., 5/8 in. Slot head screwdrivers; 1/8 in. wide, 1/4 in. wide External retaining ring pliers (STANLEY-PROTO #393 or equivalent) Feeler gauge set (0.030 in. [0.76 mm] and in. [1.91 mm]) Feeler gauge set (0.010 in. [0.25 mm]) Mechanical Latch 2 in. C-Clamp Armature clamping fixture (Allen-Bradley Part No ) Digital caliper capable of depth measurement High potential tester Rockwell Automation Publication 1502-UM052J-EN-P - December

36 Chapter 4 Maintenance Recommended Torque Values Part of the contactor may have to be disassembled for maintenance or replacement. There are appropriate torque requirements for particular bolt sizes when reassembling the contactor. Use the torque values that are specified in Table 9. Table 9 - Torque Values #10 in. Hardware 2.7 lb ft (3.6 N m) 1/4 in. Hardware 6 lb ft (8 N m) 5/16 in. Hardware (Grade 2) (1) 11 lb ft (15 N m) 5/16 in. Hardware (Grade 5) (2) 18 lb ft (24 N m) 3/8 in. Hardware 20 lb ft (27 N m) (1) All 5/16 hardware is Grade 2 unless otherwise specified. (2) See Figure 22. Routine Maintenance ATTENTION: Before performing any maintenance on the contactor, refer to the User Manual of the starter configuration. Failure to do so can result in injury to personnel or damage to the controller or contactor. ATTENTION: To avoid shock hazards, lockout incoming power and disconnect the control plug from the contactor before working on the unit. Verify with a hot stick or meter that all circuits are voltage free. Failure to do so can result in severe burns, injury, or death. The following must be performed annually or whenever a contactor is serviced: Cleaning 1. Clean all metal chips or filings from around the electromagnet assembly (coil core pole face and mating armature plate) as they can affect proper operation of the contactor. Vacuum clean if necessary. IMPORTANT Do not use compressed air to clean or remove dirt from surfaces or the enclosure. 2. If the vacuum bottles are dirty, clean the white ceramic area with a clean lint-free cloth. 36 Rockwell Automation Publication 1502-UM052J-EN-P - December 2017

37 Maintenance Chapter 4 Main Contact Inspection Visually inspect the wear of the main contacts with the contactor energized. When any part of the wear indicator line, located on the front side of the shaft, moves up into the bearing, replace all three vacuum bottles (Figure 20). Figure 20 - Vacuum Bottle Wear Indicator Vacuum Bottle Bearing Wear indicator line on operating shaft HiPot and Insulation Resistance Test The internal dielectric condition and vacuum integrity of the vacuum bottles is determined by this test. See page 18 to check the vacuum bottle integrity. See page 20 to check the insulation resistance. Lubrication Using AeroShell No. 7 (1 oz tube, Part No ), grease the actuator plate where the overtravel springs and washers make contact (Figure 21). Rockwell Automation Publication 1502-UM052J-EN-P - December

38 Chapter 4 Maintenance Figure 21 - Grease Locations Insulator Grease Actuator Plates Grease IMPORTANT Do not grease the armature shaft plastic bearings. These bearings are selflubricating and do not require grease. Vacuum Bottle Replacement Do not replace the vacuum bottles in the field. If the vacuum bottles need to be replaced, remove and return the vacuum contactor to Rockwell Automation for refurbishment. Coil Replacement Procedure See Spare Parts on page 54 for the part numbers that are required for this procedure. 1. Remove the auxiliary actuator, front stop bracket, and armature plate as shown in Figure 22. Do not remove the bolts that secure the stop bracket. Loosen them and slide out the bracket. 38 Rockwell Automation Publication 1502-UM052J-EN-P - December 2017

39 Maintenance Chapter 4 Figure 22 - Access to Coils Grade 5 (5/16 in. Hardware) to mount return spring actuator plate Grade 5 (5/16 in. Hardware) to mount armature plate Auxiliary Actuator Armature Plate Armature Stop Bracket Stop Bracket Bolts Return Spring Actuator Plate 2. Remove the retaining ring from the core of the coil you wish to replace as shown in Figure Loosen the auxiliary assembly retaining bolt and slide the assembly and the coils forward and out of the contactor as shown in Figure 23. Figure 23 - Coil Removal Operating Coil Operating Coil Retaining Ring Auxiliary Assembly Retaining Bolt Auxiliary Assembly 4. Disconnect the coil leads (take note of their location). Connect the leads of the new coil making sure that all metal-oxide varistors (MOVs) and/ or diodes are secure. See the appropriate wiring diagram in this manual for further control wiring details (page 24). 5. Slide the new coil into position and install the retaining ring on the core. Install the auxiliary assembly leaving the retaining bolt loose for adjustment later. See the Auxiliary Contact Setup Procedure (page 40) for determining the position of the auxiliary assembly. Rockwell Automation Publication 1502-UM052J-EN-P - December

40 Chapter 4 Maintenance 6. Install the armature plate, auxiliary actuator and stop bracket. Position the stop bracket by resting it lightly against the armature plate. IMPORTANT This procedure applies to adjustment of existing auxiliaries and installation of new auxiliaries. Under normal conditions, auxiliaries last at least 1,000,000 operations. If auxiliary contacts must be replaced, discard the entire assembly and install a new assembly. Discarding the entire assembly is easier than replacing one contact block. Auxiliary Contact Setup Procedure See Spare Parts on page 54 for part numbers required for this procedure. To facilitate the set-up procedure, the contactor is held closed mechanically with a clamping fixture (Figure 24). It is important that the contactor is held closed tightly with the armature plate against the magnet cores when gauging the overtravel and auxiliary positioning. To aid in closing the contactor mechanically, a clamping fixture is required. Allen-Bradley part number is recommended. Figure 24 - Contactor Components Auxiliary Actuator Armature Plate Armature Stop Bracket 1. Loosen the nuts on auxiliary assembly retaining bolt. This requires loosening and removal of the first nut that secures a ground wire at this location. Leave the nut loosened enough to permit the assembly to slide along the adjustment slot as shown in Figure Rockwell Automation Publication 1502-UM052J-EN-P - December 2017

41 Maintenance Chapter 4 Figure 25 - Auxiliary Contact Adjustment Auxiliary Assembly Retaining Bolt 2. Slide the clamping fixture (part number ) over the top of the armature stop bracket (Figure 26). Finger-tighten the two outside fixture mounting bolts against the armature stop bracket. You might have to push the armature plate a little to the rear to put the clamp in place. Figure 26 - Clamping Contactor Closed Contactor Clamping Fixture 3. Place a 5/8 in. wrench on the main shaft of the contactor, pull-down and close the contactor (Figure 27) while finger-tightening the top middle screw on the clamping fixture. ATTENTION: Do not bend the actuator stop plate. Rockwell Automation Publication 1502-UM052J-EN-P - December

42 Chapter 4 Maintenance Figure 27 - Closing the Contactor 4. After the top screw is finger tight, continue to tighten this screw with a hand tool. The armature stop bracket flexes a little, which is acceptable, but do not overtighten and bend the armature stop plate. It is important that the armature plate is held tightly against the magnet cores. The contactor must be fully closed. 5. Place a wide blade in. (0.76 mm) feeler gauge between the plastic auxiliary actuator tips and the steel actuator plate. To aid the installation of the feeler gauge, the gauge can be put in place as the clamping block screw is being finger-tightened (Step 3). See Figure 28 and Figure 29. Figure 28 - Gauging the Contacts 42 Rockwell Automation Publication 1502-UM052J-EN-P - December 2017